Wear-resistant decorative laminates

Description

BACKGROUND OF THE INVENTION

[0001] This invention relates generally to wear resistant decorative laminates having excellent scratch and abrasion resistance. More particularly, this invention relates to wear resistant, decorative laminates including a protective coating thereon which comprises a mixture of different sized mineral particles.

[0002] Decorative laminates are known in the art for use as surfaces for counter tops, table tops, furniture, and the like. Such decorative laminates are typically comprised of a core formed from a plurality of sheets of Kraft paper which are impregnated with a resin. Positioned above the core is a decorative sheet which is typically a cellulose pigmented paper containing a print, pattern, or solid color which may also be impregnated with a resin. The decorative sheet is generally covered with a transparent or semi-transparent protective overlay sheet comprising a cellulose paper impregnated with a phenolic resin such as melamine-formaldehyde. The overlay sheet protects the decorative sheet from abrasion, scratches, chemicals, burns, and the like.

[0003] The decorative laminates are typically made by stacking the core, decorative sheet, and overlay sheet, and then inserting the stack between pressing plates at a temperature and pressure sufficient to cause the laminating resins to flow and cure between the respective layers. When making the decorative laminates, it is often desirable to coat the back (under) side and/or the top side of the overlay sheet with a resin containing small particles of abrasive materials such as silica or alumina in order to improve the abrasion resistance of the laminate.

[0004] However, it has been found that the incorporation of such abrasive minerals into the overlay sheet can cause severe damage to the delicate, highly polished or intricately etched surfaces of the press plates. Many attempts have been made to overcome this problem. See, for example, U.S. Patent No. 5,558,906, which teaches the use of an abrasion resistant coating comprising a thermoset resin, a mixture of alumina particles, a silane coupling agent, and a thickening agent which functions to suspend the alumina particles and protect the press plates. Others have addressed the problem by treating the surfaces of the press plates to make them more resistant to scratching. See U.S. Patent No. 6,656,329. Still others have attempted to use smaller sized mineral particles in an effort to protect the plates. See U.S. Patent No. 5,141,799, which teaches the use of amorphous silica powder having a particle size range from about 0.01 to 0.05 microns. However, the particles must be applied as an agglomerate having a composite size between 12 to 30 microns in order to provide sufficient abrasion resistance.

[0005] U.S Patent No. 4,971,855 teaches a wear-resistant glossy decorative laminate (10) that has an upper facing surface having an ultra-thin wear resistant layer that comprises abrasion resistant particles having a maximum particle size of up to 7 microns being held in place by a binder material.

[0006] Accordingly, there is still a need in the art for a coating for use on decorative laminates which imparts scratch and abrasion resistance to the laminate but does not damage press plates during manufacture of the laminate.

SUMMARY OF THE INVENTION

[0007] Embodiments of the present invention meet that need by providing a decorative laminate that includes a coating on the exterior surface of the laminate that comprises a mixture of mineral particles having different particle sizes. Such a laminate exhibits improved glass scratch, mar, and scuff resistance as compared to prior art laminate constructions. The present invention is not limited to high pressure laminates, but also includes melamine faced chip board, thermal fused melamine laminates, and continuous pressed laminates.

[0008] According to one aspect of the present invention, a decorative laminate having resistance to abrasion and scratching is provided and comprises a substrate, a decorative sheet on the substrate, and a coating on the decorative sheet. The coating comprises a mixture of first mineral particles having a particle size in the range from 3µm (microns) to 8µm (microns) and second mineral particles having a particle size of less than 1.0µm (micron), and a binder for said first and second mineral particles.

[0009] In a preferred form, the first and second mineral particles comprise alumina particles, with the second mineral particles comprising sol gel process alumina particles. Generally, the binder comprises a phenolic resin or a melamine formaldehyde resin.

[0010] In another embodiment, the laminate further includes an overlay sheet having first and second major surfaces. The overlay sheet is positioned between the decorative sheet and the coating of the mixture of first and second mineral particles such that the coating of the mixture of first and second mineral particles is on the second major surface of the overlay sheet. The first major surface of the overlay sheet faces the decorative sheet and also includes a coating thereon comprising mineral particles having a particle size in the range from 10µm (microns) to 30µm (microns) along with a binder for the mineral particles. Preferably, the mineral particles on the first major surface of the overlay sheet comprise alumina particles.

[0011] In a second aspect of the invention, a method of making a decorative laminate having resistance to abrasion and scratching is provided comprising providing a substrate, a decorative sheet on said substrate, coating said decorative sheet with a coating comprising mineral particles in a binder, and placing said decorative sheet on said substrate to form a stack. Heat and pressure is applied to said stack in an amount sufficient to cure said binder. Said coating on said decorative sheet comprises a mixture of first mineral particles having a particle size in the range from 3µm (microns) to 8µm (microns) and second mineral particles having a particle size of less than 1.0 µm (micron).

[0012] The substrate is preferably impregnated with a resin prior to forming the stack. Preferably, the mixture of the first and second mineral particles comprise alumina particles, and the second mineral particles comprise sol gel process alumina particles. Generally, the binder for the mineral particles comprises a phenolic resin or a melamine formaldehyde resin.

[0013] In another embodiment, the method of making a decorative laminate further comprises providing an overlay sheet having first and second major surfaces, coating the first major surface of the overlay sheet with a coating comprising mineral particles having a particle size in the range from 10µm (microns) to 30µm (microns) and a binder for said mineral particles, and coating the second major surface of the overlay sheet with a coating comprising a mixture of first mineral particles having a particle size in the range from 3µm (microns) to 8µm (microns) and second mineral particles having a particle size of less than 1.0µm (micron), and a binder for the mineral particles. The overlay sheet is placed on the decorative sheet such that the first major surface of the overlay sheet faces the decorative sheet and such that the substrate, decorative sheet, and overlay sheet form a stack. Heat and pressure are applied to the stack in an amount sufficient to cure the binder and form the laminate.

[0014] In a preferred form, the method includes applying heat to the first and second major surfaces of the overlay sheet prior to placing the overlay sheet on the decorative sheet. Also, the substrate is preferably impregnated with a resin prior to forming the stack. Preferably, the mineral particles coated on the second major surface of the overlay sheet comprise alumina particles, and the alumina particles having a particle size of less than 1.0µm (micron) comprise sol gel process alumina particles.

[0015] Accordingly, it is a feature of embodiments of the present invention to provide a decorative laminate including a coating thereon which provides resistance to abrasion and scratching and which comprises different sized mineral particles. These, and other features and advantages of embodiment of the present invention will become apparent from the following detailed description, the accompanying drawings, and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] 

Fig. 1 is a cross-sectional view of one embodiment of the decorative laminate of the present invention;

Fig. 2 is a cross-sectional view of another embodiment of the decorative laminate of the present invention; and

Fig. 3 is a schematic illustration of a method of making one embodiment of the decorative laminate of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0017] We have found that improved scratch and abrasion resistance, specifically improved glass scratch, mar, and scuff resistance, can be provided to decorative laminates by providing a coating of mineral particles on both sides of the overlay sheet, where the coating on the top (exterior-facing) side of the sheet comprises a mixture of mineral particles having a particle size of from between about 3-8 microns and mineral particles having a particle size of less than about 1.0 micron. Preferably, the particle size is between about 0.2 and 0.5 micron. Further, the exterior-facing coating imparts enhanced protection against scratching of the polished metal press plates used to form the laminate. Without wishing to be limited to a specific theory, it is believed that the mixture of larger and very small particles almost immediately forms a tough, hydrophobic film on top of the resin binder when applied to the laminate.

[0018] Further, in a preferred embodiment of the invention, the smaller mineral particles comprise sol gel process alumina. Again, without wishing to be limited a particular theory, it is believed that traces of nitric acid used in typical washing processes during sol gel formation of the particles, act as a catalyst for the resin binder and promote enhanced localized curing of the resin. This is believed to result in a tougher cured resin which renders the laminate more resistant to scratching and marring. Further, the smaller sol gel process particles are believed to form a film that entraps the larger mineral particles in the film at the surface of the laminate. These larger particles are also believed to contribute to the resulting improvement in scratch and mar resistance of the laminate.

[0019] Referring now to Fig. 1, one embodiment of the decorative laminate 10 of the present invention is shown. This embodiment is useful when the decorative sheet is a solid color, and an overlay sheet may be omitted. The laminate comprises a substrate 12, a decorative sheet 14 on the substrate, and a mineral particle-filled cured resin coating layer 24.

[0020] As shown, the substrate or core 12 of the decorative laminate is preferably comprised of one or more layers of paper sheets such as Kraft paper which have been impregnated with a liquid thermosetting resin such as a phenolic resin or a melamine formaldehyde resin. The substrate or core provides a reinforcing structural base to the laminate. The substrate may also include one or more additional layers such as bleached Kraft paper, mineral fiber cement board, MDF board, and any other material used in the industry. A preferred structure for the substrate layer is from about 2-100 sheets of 40-300 g/m² basis weight Kraft paper impregnated with a phenolic resin, a melamine formaldehyde resin, or blends thereof. Typically, the resin will have a solids content of from about 20 to about 40% based on the total weight of the core.

[0021] The decorative sheet 14 in this embodiment is a pigmented solid color sheet comprised of cellulose and having a basis weight in the range of from about 55 to about 200 gm/m². Decorative sheet 14 may also optionally be impregnated with a curable resin.

[0022] The exterior facing surface of decorative sheet 14 is coated with a coating 24 comprising a mixture of first alumina particles having a particle size of from between about 3-8 microns and second alumina particles having a particle size of less than about 1.0 micron, preferably from about 0.1 to 1.0, and most preferably from about 0.3 to about 0.5 microns, and a binder for the particles. Generally, the resin binder will comprise a melamine formaldehyde resin. The first alumina particles are commercially available from Micro Abrasives Corp., Westfield, MA, under the trade name Microgrit. The second alumina particles preferably comprise sol gel process alumina, which is commercially available from Sasol North America, Houston, TX under the trade name Sol DISPAL. The alumina particles made by a sol gel process most preferably have a particle size of about 0.5 microns. The coating containing the mixture of alumina particles is preferably prepared by mixing the larger and smaller particles with the resin binder using substantially constant agitation to evenly disperse the particles in the binder.

[0023] Referring now to Fig. 2, another embodiment of decorative laminate 10' is shown. In this embodiment, the laminate comprises a substrate 12, a decorative sheet 14 on the substrate, and an overlay sheet 16. As previously described, substrate 12 includes one or more sheets that have been impregnated with a resin. In this embodiment, decorative sheet 14 comprises a cellulosic sheet printed with a decorative pattern or design. Overlay sheet 16 preferably comprises a cellulose paper sheet which includes a first surface 18 and second surface 20.

[0024] The first surface 18 of the overlay sheet includes a coating 22 comprising mineral particles having a particle size of from between about 10-30 microns and a binder for the mineral particles. Preferred mineral particles for use in the present invention are alumina particles. Alumina particles having a particle size of from 10-30 microns are commercially available from Micro Abrasive Corp. The binder is preferably a phenolic or melamine formaldehyde resin. Such resins are commercially available from a number of manufacturers including Borden Chemicals and Dynea International Oy. The coating is preferably prepared by mixing the alumina particles and resin binder with agitation to disperse the particles evenly throughout the resin.

[0025] Fig. 3 illustrates an embodiment of the method of making the decorative laminate of the present invention which is shown as a continuous process. However, it is contemplated that individual layers in the laminate may be produced at separate times (and even at separate locations) and stored prior to being formed into the final laminate. As shown, the substrate 12 is formed by impregnating a web of Kraft paper 26 (or other suitable core material as described above) with a liquid resin. Typically, the liquid resin is supplied as an aqueous solution containing about 40-60% resin solids. The paper 26 is fed in a continuous manner and impregnated with resin at station 28. A number of conventional impregnation techniques may be utilized including immersion or dip coating of paper 26. After impregnation, the paper web 26 is preferably at least partially dried in a hot air oven 30 to drive off volatiles. Web 26 is then cut into individual sheets 12 to form the core or substrate portion of the laminate.

[0026] Decorative sheet 14 is also supplied from a roll of material as a continuous web. In the embodiment shown, decorative sheet 14 comprises a solid pigmented color material. Decorative sheet 14 is impregnated with liquid resin at coating station 32, followed by at least partial drying in a hot air oven 34. As shown in Fig. 3, the top (exterior facing) surface of decorative sheet 14 is then coated with a mixture of first alumina particles having a particle size of from between about 3-8 microns and second alumina particles having a particle size of less than about 1.0 micron, preferably from about 0.1 to 1.0, and most preferably from about 0.3 to about 0.5 microns, and a resin binder for the particles as previously described.

[0027] The particles dispersed in the resin binder are applied using a wire-wound metering rod 33 (also known as a Meyer rod or bar). Other coating techniques may be used. The coating is applied to provide a final coating having a dry basis weight of from about 15 to about 30 g/m². Preferably, the coating is supplied as particles of alumina or corundum in an approximately 1% -10% aqueous resin solution. The coated web is dried in a hot air oven 36 to drive off volatile components. The coated web is then cut into individual decorative sheets 14. A decorative sheet is then assembled in a stack with multiple substrate sheets 12. The stack is then cured to its final laminate form using heat and pressure at curing station 40. Typically, curing station 40 will include an opposing pair of polished metal press plates, 50, 51.

[0028] Optionally, the laminate may include an overlay sheet 16. This embodiment is shown using a phantom line in Fig. 3 to add the overlay sheet to the stack. If an overlay sheet is used, then decorative sheet 14 is impregnated with resin, but not coated with the mixture of alumina particles. Rather, as shown, overlay sheet 16 is supplied as a continuous web from a roll of material and is impregnated with a liquid resin at station 41. the impregnated web is then fed between coating rods 42, 44 such that the first (interior facing) surface is coated with coating from rod 42 and the second (exterior facing) surface is coated with coating from roller 44.

[0029] The coating from rod 42 comprises mineral particles having a particle size of from between about 10-30 microns dispersed in a liquid resin binder for the mineral particles. The coating is preferably applied at a coat weight to provide a final dried coating weight of from between about 10 to about 30 g/m². The coating from rod 44 comprises the mixture of different sized mineral particles dispersed in a liquid resin binder as described above. The coating from rod 44 is applied to provide a final dried coat weight of from about 15 to about 30 g/m². The overlay sheet 16 is then at least partially dried in a hot air oven 46 to drive off volatile components.

[0030] The coated web is then cut into individual overlay sheets 16 and, in this alternative embodiment, an overlay sheet is placed on top of the substrate and decorative layers 12 and 14. The stack is then placed between press plates 50, 51 at curing station 40 under heat and pressure to cure the resin in each of the layers and form the finished laminate 10.

[0031] In order that the invention may be more readily understood, reference is made to the following example which is intended to be illustrative of specific embodiments of the invention, but is not intended to be limiting in scope.

Example 1

[0032] Laminates were prepared in accordance with an embodiment of the present invention, the laminates included a substrate layer comprised of multiple sheets of resin-impregnated Kraft paper, a cellulosic decorative sheet, and an overlay sheet having scratch and abrasion resistant coatings on its first (interior facing) and second (exterior facing) surfaces with the following formulations: The first surface coating included alumina particles having an average particle size of about 15 microns dispersed in a melamine formaldehyde resin (50% resin solids/50% water). The coating was applied to provide a final dried coat weight of about 17 g/m². The second surface coating included a mixture of alumina particles, the first alumina particles having an average particle size of about 3 microns, and the second alumina particles having an average particle size of about 0.5 microns. The alumina particles were dispersed in a melamine formaldehyde resin (50% resin solids/50% water). The coating was applied to provide a final coat weight of 22 g/m².

[0033] Each of the laminate samples prepared above was subjected to the following test procedures:

Glass Scratch Test

[0034] This test measured the ease with which a laminate could be scratched using a material of similar sharpness and hardness to ordinary silica, the usual scratching component in air-borne dirt. The test was carried out pursuant to the procedures used in the National Electrical Manufacturers Association (NEMA) Linear Glass Scratch Resistance test (LD3-2000). For comparison purposes, a conventional laminate having a melamine formaldehyde resin top coat, but no mineral particles, was also tested. The laminate surfaces were observed visually after being scratched with the edge of a glass slide mounted in a scratch tool fixture to which different loads could be applied. The conventional laminate could withstand a load of only 10-40 grams before visible scratch marks were observed. The laminate made in accordance with an embodiment of the present invention as described above did not exhibit visible scratch marks until the load was increased to 150-200 grams or above.

Diamond Scratch Test

[0035] This test measured the ability of the surface of the decorative laminate to resist scratching in accordance with European Standard EN 438-1. A load was applied to a diamond point mounted to a fixture which made a circular motion on the surface of a laminate sample. Again, for comparison purposes, a conventional laminate having a melamine formaldehyde resin top coat, but no mineral particles, was also tested. The laminate surface were observed visually after being scratched. For the test, dark-colored decorative laminates were used. Scratch marks are more readily perceived when viewing a darker surface. The conventional laminate showed visible scratch marks with an applied force of 1.5-1.75 Newtons. The laminate made in accordance with an embodiment of the present invention as described above did not exhibit visible scratch marks until the force applied reached 2.25-2.5 Newtons.

Mar Resistance Test

[0036] The mar resistance of a conventional laminate sample and a laminate prepared in accordance with an embodiment of the present invention as described above were determined by rubbing the laminate surface under controlled conditions with an abrasive pad (ScotchBrite® brand), and then measuring the change in surface gloss of the marred area as compared with the original surface gloss. The change in surface gloss was measured by a standard glossmeter. After 5 rubs using the abrasive pad, the conventional laminate exhibited a measured 15-20% reduction in gloss. After 5 rubs, the laminate of the present invention exhibited less than a 5% reduction in gloss.

Claims

1. A decorative laminate (10) having resistance to abrasion and scratching comprising:

a substrate (12);

a decorative sheet (14) on said substrate; and

a coating (24) on said decorative sheet (14);

characterized in that said coating (24) comprises a mixture of first mineral particles having a particle size in the range from 3µm (microns) to 8µm (microns), and second mineral particles having a particle size of less than 1.0 µm (micron), and a binder for said first and second mineral particles.

2. A decorative laminate (10) as claimed in Claim 1, wherein said first and second mineral particles comprise alumina particles.

3. A decorative laminate (10) as claimed in Claim 1 or Claim 2, wherein said second mineral particles comprise sol gel process alumina particles.

4. A decorative laminate (10) as claimed in any of Claims 1 to 3, wherein said binder comprises a phenolic resin or a melamine formaldehyde resin.

5. A decorative laminate (10) as claimed in any of Claims 1 to 4, further including an overlay sheet (16) having first (18) and second (20) major surfaces, said overlay sheet (16) being positioned between said decorative sheet (14) and said coating (24) of a mixture of first and second mineral particles such that said coating (24) of a mixture of first and second mineral particles is on said second major surface (20) of said overlay sheet (16); said first major surface (18) of said overlay sheet (16) faces said decorative sheet (14) and includes a coating (22) thereon, said coating (22) comprising mineral particles having a particle size in the range from 10µm (microns) to 30µm (microns) and a binder for said mineral particles.

6. A decorative laminate (10) as claimed in Claim 5, wherein said mineral particles comprising a coating (22) on said first major surface (18) of said overlay sheet (16) comprise alumina particles.

7. A method of making a decorative laminate (10) having resistance to abrasion and scratching comprising:

providing a substrate (12);

providing a decorative sheet (14) on said substrate;

coating said decorative sheet (14) with a coating (24) comprising mineral particles in a binder;

placing said decorative sheet (14) on said substrate (12) to form a stack; and

applying heat and pressure to said stack in an amount sufficient to cure said binder; characterized in that said coating (24) on said decorative sheet (14) comprises a mixture of first mineral particles having a particle size in the range from 3µm (microns) to 8µm (microns) and second mineral particles having a particle size of less than 1.0 µm (micron).

8. A method as claimed in Claim 7, including impregnating said substrate (12) with a resin.

9. A method as claimed in Claim 7 or Claim 8, wherein said mixture of said first and second mineral particles comprise alumina particles.

10. A method as claimed in any of Claims 7 to 9, wherein said second mineral particles comprise sol gel process alumina particles.

11. A method as claimed in any of Claims 7 to 10, wherein said binder comprises a phenolic resin or a melamine formaldehyde resin.

12. A method as claimed in Claim 7, further including providing an overlay sheet (16) having first (18) and second (20) major surfaces; coating said first major surface (18) of said overlay sheet (16) with a coating (22) comprising mineral particles having a particle size in the range from 10µm (microns) to 30µm (microns) and a binder for said mineral particles;
coating said second major surface (20) of said overlay sheet (16) with said coating (24) comprising a mixture of first mineral particles having a particle size in the range from 3µm (microns) to 8µm (microns) and second mineral particles having a particle size of less than 1.0 µm (micron), and a binder for said mineral particles;
placing said overlay sheet (16) on said decorative sheet (14) such that said first major surface (18) of said overlay sheet (16) faces said decorative sheet (14) and such that said substrate, decorative sheet (14), and overlay sheet (16) form a stack; and
applying heat and pressure to said stack in an amount sufficient to cure said binder.

13. A method as claimed in Claim 12 including applying heat to said first (18) and second (20) major surfaces of said overlay sheet (16) prior to placing said overlay sheet (16) on said decorative sheet (14).

14. A method as claimed in Claim 12 or Claim 13 wherein said mineral particles coated on said second major surface (20) of said overlay sheet (16) comprise alumina particles.

15. A method as claimed in any of Claims 12 to 14 wherein said alumina particles having a particle size of less than 1.0 µm (micron) comprise sol gel process alumina particles.

Ansprüche

1. Dekoratives Laminat (10) mit Beständigkeit gegen Abrieb und Zerkratzen, umfassend:

ein Substrat (12);

einen dekorativen Bogen (14) auf dem Substrat und

eine Beschichtung (24) auf dem dekorativen Bogen (14);

dadurch gekennzeichnet, dass die Beschichtung (24) eine Mischung aus ersten Mineralpartikeln mit einer Partikelgröße im Bereich von 3 µm (Mikrometer) bis 8 µm (Mikrometer) und zweiten Mineralpartikeln mit einer Partikelgröße von unter 1,0 µm (Mikrometer) und ein Bindemittel für die ersten und zweiten Mineralpartikel umfaßt.

2. Dekoratives Laminat (10) nach Anspruch 1, wobei die ersten und zweiten Mineralpartikel Aluminiumoxidpartikel umfassen.

3. Dekoratives Laminat (10) nach Anspruch 1 oder 2, wobei die zweiten Mineralpartikel Sol-Gel-Prozess-Aluminiumoxidpartikel umfassen.

4. Dekoratives Laminat (10) nach einem der Ansprüche 1 bis 3, wobei das Bindemittel ein Phenolharz oder ein Melamin-Formaldehyd-Harz umfasst.

5. Dekoratives Laminat (10) nach einem der Ansprüche 1 bis 4, weiterhin mit einem Deckbogen (16) mit einer ersten (18) und zweiten (20) Hauptoberfläche, wobei der Deckbogen (16) zwischen dem dekorativen Bogen (14) und der Beschichtung (24) aus einer Mischung aus ersten und zweiten Mineralpartikeln positioniert ist, so dass die Beschichtung (24) aus einer Mischung aus ersten und zweiten Mineralpartikeln sich auf der zweiten Hauptoberfläche (20) des Deckbogens (16) befindet; die erste Hauptoberfläche (18) des Deckbogens (16) dem dekorativen Bogen (14) zugewandt ist und eine Beschichtung (22) darauf enthält, wobei die Beschichtung (22) Mineralpartikel mit einer Partikelgröße im Bereich von 10 µm (Mikrometer) bis 30 µm und ein Bindemittel für die Mineralpartikel umfaßt.

6. Dekoratives Laminat (10) nach Anspruch 5, wobei die Mineralpartikel, die eine Beschichtung (22) auf der ersten Hauptoberfläche (18) des Deckbogens (16) umfassen, Aluminiumoxidpartikel umfassen.

7. Verfahren zum Herstellen eines dekorativen Laminats (10) mit Beständigkeit gegen Abrieb und Zerkratzen, umfassend:

Bereitstellen eines Substrats (12);

Bereitstellen eines dekorativen Bogens (14) auf dem Substrat;

Beschichten des dekorativen Bogens (14) mit einer Beschichtung (24), die Mineralpartikel in einem Bindemittel umfaßt;

Platzieren des dekorativen Bogens (14) auf dem Substrat (12) unter Ausbildung eines Stapels; und

Einwirkenlassen von Hitze und Druck auf den Stapel in einem Ausmaß, das ausreicht, das Bindemittel zu härten; dadurch gekennzeichnet, dass die Beschichtung (24) auf dem dekorativen Bogen (14) eine Mischung aus ersten Mineralpartikeln mit einer Partikelgröße im Bereich von 3 µm (Mikrometer) bis 8 µm (Mikrometer) und zweiten Mineralpartikeln mit einer Partikelgröße von unter 1,0 µm (Mikrometer) umfaßt.

8. Verfahren nach Anspruch 7, mit dem Imprägnieren des Substrats (12) mit einem Harz.

9. Verfahren nach Anspruch 7 oder 8, wobei die Mischung aus den ersten und zweiten Mineralpartikeln Aluminiumoxidpartikel umfasst.

10. Verfahren nach einem der Ansprüche 7 bis 9, wobei die zweiten Mineralpartikel Sol-Gel-Prozess-Aluminiumoxidpartikel umfassen.

11. Verfahren nach einem der Ansprüche 7 bis 10, wobei das Bindemittel ein Phenolharz oder ein Melamin-Formaldehyd-Harz umfasst.

12. Verfahren nach Anspruch 7, weiterhin mit dem Bereitstellen eines Deckbogens (16) mit einer ersten (18) und zweiten (20) Hauptoberfläche;
Beschichten der ersten Hauptoberfläche (18) des Deckbogens (16) mit einer Beschichtung (22), die Mineralpartikel mit einer Partikelgröße im Bereich von 10 µm (Mikrometer) bis 30 µm (Mikrometer) und ein Bindemittel für die Mineralpartikel umfaßt;
Beschichten der zweiten Hauptoberfläche (20) des Deckbogens (14) mit der Beschichtung (24), die eine Mischung aus ersten Mineralpartikeln mit einer Partikelgröße im Bereich von 3 µm (Mikrometer) bis 8 µm (Mikrometer) und zweiten Mineralpartikeln mit einer Partikelgröße von unter 1,0 µm (Mikrometer) und ein Bindemittel für die Mineralpartikel umfaßt;
Platzieren des Deckbogens (16) auf dem dekorativen Bogen (14), so dass die erste Hauptoberfläche (18) des Deckbogens (16) dem dekorativen Bogen (14) zugewandt ist und so dass das Substrat, der dekorative Bogen (14) und der Deckbogen (16) einen Stapel bilden; und
Einwirkenlassen von Hitze und Druck auf den Stapel in einem Ausmaß, das ausreicht, das Bindemittel zu härten.

13. Verfahren nach Anspruch 12 mit dem Einwirkenlassen von Hitze auf die erste (18) und zweite (20) Hauptoberfläche des Deckbogens (16) vor dem Platzieren des Deckbogens (16) auf dem dekorativen Bogen (14).

14. Verfahren nach Anspruch 12 oder 13, wobei die auf die zweite Hauptoberfläche (20) des Deckbogens (16) aufgebrachten Mineralpartikel Aluminiumoxidpartikel umfassen.

15. Verfahren nach einem der Ansprüche 12 bis 14, wobei die Aluminiumoxidpartikel mit einer Partikelgröße von unter 1,0 µm (Mikrometer) Sol-Gel-Prozess-Aluminiumoxidpartikel umfassen.

Revendications

1. Stratifié décoré (10), ayant une résistance à l'abrasion et aux rayures constitué des éléments suivants:

un substrat (12);

une feuille décorée (14) disposée sur ledit substrat; et

un revêtement (24) disposé sur ledit feuillet décoré (14);

caractérisé en ce que ledit revêtement (14) est constitué d'un mélange de premières particules minérales ayant une granulométrie dans la gamme de 3 µm (microns) à 8 µm (microns), de secondes particules minérales ayant une granulométrie inférieure à 1,0 µm (micron), et d'un liant pour lesdites premières et secondes particules minérales.

2. Stratifié décoré (10) selon la revendication 1, dans lequel lesdites premières et secondes particules minérales sont constituées de particules d'alumine.

3. Stratifié décoré (10) selon la revendication 1 ou la revendication 2, dans lequel lesdites secondes particules minérales sont constituées de particules d'alumine obtenues par procédé sol-gel.

4. Stratifié décoré (10) selon l'une quelconque des revendications 1 à 3, dans lequel le liant est constitué d'une résine phénolique ou d'une résine mélamine-formaldéhyde.

5. Stratifié décoré (10) selon l'une quelconque des revendications 1 à 4, comprenant en outre une pellicule de recouvrement (16) ayant une première (18) et une seconde (20) surfaces principales, ladite pellicule de recouvrement (16) étant positionnée entre ladite feuille décorée (14) et ledit revêtement (24) d'un mélange de premières et de secondes particules minérales tel que ledit revêtement (24) d'un mélange de premières et de secondes particules minérales est disposé sur ladite seconde surface principale (20) de ladite pellicule de recouvrement (16); ladite première surface principale (18) de ladite pellicule de recouvrement (16) revêt ladite feuille décorée (14) et comprend un revêtement (22) disposé sur elle, ledit revêtement (22) étant constitué de particules minérales ayant une granulométrie dans la gamme de 10 µm (microns) à 30 µm (microns) et d'un liant pour lesdites particules minérales.

6. Stratifié décoré (10) selon la revendication 5, dans lequel lesdites particules minérales sont constituées d'un revêtement (22) disposé sur ladite première surface principale (18) de ladite pellicule de recouvrement (16) sont constituées de particules d'alumine.

7. Méthode de réalisation d'un stratifié décoré (10) ayant une résistance à l'abrasion et aux rayures constituée des éléments suivants:

la fourniture d'un substrat (12);

la fourniture d'une feuille décorée (14) disposée sur ledit substrat;

le revêtement de ladite feuille décorée (14) par un revêtement (24) constitué de particules minérales dans un liant;

le placement de ladite feuille décorée (14) sur ledit substrat (12) pour former un empilement; et l'application de chaleur et de pression audit empilement en quantité suffisante pour polymériser ledit liant; caractérisé en ce que ledit revêtement (24) disposé sur ladite feuille décorée (14) est constitué d'un mélange de premières particules minérales ayant une granulométrie dans la gamme de 3 µm (microns) à 8 µm (microns) et de secondes particules minérales ayant une granulométrie inférieure à 1,0 µm (micron).

8. Méthode selon la revendication 7, comprenant l'imprégnation dudit substrat (12) par une résine.

9. Méthode selon la revendication 7 ou la revendication 8, dans laquelle ledit mélange desdites premières et secondes particules minérales est constitué de particules d'alumine.

10. Méthode selon l'une quelconque des revendications 7 à 9, dans laquelle lesdites secondes particules minérales sont constituées de particules d'alumine obtenues par procédé sol-gel.

11. Méthode selon l'une quelconque des revendications 7 à 10, dans laquelle le liant est constitué d'une résine phénolique ou d'une résine mélamine-formaldéhyde.

12. Méthode selon la revendication 7, comprenant en outre la fourniture d'une pellicule de recouvrement (16) ayant une première (18) et une seconde (20) surfaces principales, le revêtement de ladite première surface principale (18) de ladite pellicule de recouvrement (16) par un revêtement (22) constitué de particules minérales ayant une granulométrie dans la gamme de 10 µm (microns) à 30 µm (microns) et d'un liant pour lesdites particules minérales;
le revêtement de ladite seconde surface principale (20) de ladite pellicule de recouvrement (16) par ledit revêtement (24) étant constitué d'un mélange de premières particules minérales ayant une granulométrie dans la gamme de 3 µm (microns) à 8 µm (microns) et de secondes particules minérales ayant une granulométrie inférieure à 1,0 µm (micron), et d'un liant pour lesdites particules minérales;
le placement de ladite pellicule de recouvrement (16) sur ladite feuille décorée (14) tel que ladite première surface principale (18) de ladite pellicule de recouvrement (16) revêt ladite feuille décorée (14) et tel que lesdits substrats, feuille décorée (14) et pellicule de recouvrement (16) forment un empilement; et
l'application de chaleur et de pression audit empilement en quantité suffisante pour polymériser ledit liant;

13. Méthode selon la revendication 12, comprenant l'application de chaleur auxdites première (18) et seconde (20) surfaces principales sur ladite pellicule de recouvrement (16) avant le placement de ladite pellicule de recouvrement (16) sur ladite feuille décorée (14).

14. Méthode selon la revendication 12 ou la revendication 13, dans laquelle lesdites particules minérales revêtues sur ladite seconde surface principale (20) de ladite pellicule de recouvrement (16) sont constituées de particules d'alumine.

15. Méthode selon l'une quelconque des revendications 12 à 14, dans laquelle lesdites particules d'alumine ayant une granulométrie inférieure à 1,0 µm (micron) sont constituées de particules d'alumine obtenues par procédé sol-gel.

Drawing